EP1099228B1 - Conducteur feuillete isole plie et son procede de fabrication - Google Patents

Conducteur feuillete isole plie et son procede de fabrication Download PDF

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Publication number
EP1099228B1
EP1099228B1 EP99934089A EP99934089A EP1099228B1 EP 1099228 B1 EP1099228 B1 EP 1099228B1 EP 99934089 A EP99934089 A EP 99934089A EP 99934089 A EP99934089 A EP 99934089A EP 1099228 B1 EP1099228 B1 EP 1099228B1
Authority
EP
European Patent Office
Prior art keywords
conductor
foil conductor
length
foil
insulated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP99934089A
Other languages
German (de)
English (en)
Other versions
EP1099228A4 (fr
EP1099228A1 (fr
Inventor
Thomas J. Lanoue
Richard P. Marek
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABB Inc
Original Assignee
ABB Inc USA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABB Inc USA filed Critical ABB Inc USA
Publication of EP1099228A1 publication Critical patent/EP1099228A1/fr
Publication of EP1099228A4 publication Critical patent/EP1099228A4/fr
Application granted granted Critical
Publication of EP1099228B1 publication Critical patent/EP1099228B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/323—Insulation between winding turns, between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation

Definitions

  • the present invention relates to a folded insulated foil conductor for use in electrical devices and more particularly to an improved folded insulated foil conductor for use in transformer coils and the method of making the same.
  • insulated conductors for electrical apparatus are made from conductor material such for example as aluminium or copper and have a substantially rectangular cross-sectional area with rounded comers. The conductor material is then insulated in a separate process. Such standard rectangular conductor only come in discrete sizes.
  • US 3,634,800 discloses a method for producing a foil conductor comprising the steps of bonding an insulative strip to a conductive strip and folding the bonded strips in order to have an insulated foil conductor.
  • US 3,902938 describes a method wherein the insulative strip is not bonded to the conductive strip, instead it is wrapped around the conductive strip.
  • slitting on the fly any foil width can be folded into near any cross-sectional size and the conductor cross-sectional area can be varied by folding the foil sheet conductor over additional foil filler strips.
  • the folded foil conductor is simultaneously insulated by folding slit sheet insulation during the same process.
  • a method of making a folded insulated foil conductor including the steps of bonding a length of sheet insulation material to a corresponding length of a foil conductor material to provide a length of flat composite foil conductor/insulation, folding the length of composite foil/conductor/insulation longitudinally into a substantially U-shaped length having a central portion between two leg portions, and folding the leg portions of the "U” inwardly to a position substantially parallel to the central portion of the "U” to bring the free ends of the leg portions into opposing relation to provide a folded insulated foil conductor having two conductor thickness surrounded by insulation.
  • the method includes the step of inserting an un-insulated filler foil conductor strip into the U-shaped length prior to folding the leg portions of the "U” to increase the conductor cross-sectional area of the folded insulated foil conductor.
  • the un-insulated filler foil conductor strip has a width corresponding to the central portion of the "U".
  • a method of making a smooth, rounded edge and tightly insulated turn conductor for distribution transformers comprising the steps of feeding a length of sheet insulation material to an assembly station, feeding a length of foil conductor material to the assembly station, at the assembly station, bonding the length of sheet insulation material to a corresponding length of the foil conductor material to provide a length of flat composite foil conductor/insulation, folding the length of composite foil conductor/insulation longitudinally into a substantially U-shaped length having a central portion between two leg portions, and folding the leg portions of the "U” inwardly to a position substantially parallel to the central portion of the "U” to bring the free ends of the leg portions into a substantially abutting relation to provide a folded insulated coil conductor having a two conductor thickness surrounded by insulation and having smooth rounded edges.
  • a folded insulated foil conductor for distribution transformers comprising a length of sheet insulation material bonded to a corresponding length of coil conductive material to provide a length of flat composite foil conductor/insulation, the length of composite conductor insulation being folded longitudinally into a substantially U-shaped length having a central portion between two leg portions, and the leg portions of the "U” being folded inwardly to a position substantially parallel to the horizontal central portion of the "U” to bring the free ends of the leg portions into opposing relation to provide a folded insulated foil conductor having two conductor thickness surrounded by insulation.
  • an un-insulated filler foil conductor strip is disposed centrally in the folded insulated foil conductor to increase the conductor cross-sectional area of the folded insulated foil conductor.
  • the insulated foil conductor includes a length of foil conductor material 10 and a length of insulation material 12.
  • the foil conductor is first slit into a predetermined width 10 and the sheet insulation material is slit into a corresponding width 12.
  • a length of the slit foil conductor material 10 and a corresponding length of the slit sheet insulation material 12 are fed to an assembly station where the length of sheet insulation material 12 and the corresponding length of foil conductor material 10 are bonded to each other to provide a length of flat composite foil conductor/insulation 14, Fig. 2.
  • a length of the composite foil conductor/insulation 14 is then fed through a suitable folding machine where it is folded longitudinally into a substantially "U" shaped length having a central portion 16 between two leg portions 18 and 20, Fig. 3.
  • the leg portions 18 and 20 of the "U” are folded inwardly to a position substantially parallel to the central portion 16 of the "U” to bring the free ends 18a, 20a of the leg portions 18 and 20 into opposing relation, Fig. 4, to provide a folded insulated foil conductor 22 having a two-conductor thickness 10 surrounded by insulation 12.
  • both the foil conductor material 10 and the sheet insulation material 12 are moving (on the fly) during the steps of slitting and bonding the materials.
  • the foil conductor material 10 and the sheet insulation material 12 in the composite foil conductor/insulation 14 are moving (on the fly) during all of the steps of the method of making the foil insulated foil conductor 22.
  • the folded insulated foil conductor of the prior art 22 is folded longitudinally such that the ends of the conductor material 10 and the ends of the insulation material 12 nearly touch in the middle, resulting in two conductor thickness' 10 surrounded by insulation 12.
  • the folding concept provides a unique method for obtaining a smooth, rounded, and tightly insulated turn conductor for distribution transformers.
  • the prior art method for achieving a smooth rounded foil edge or turn was by conditioning the edge of the conductor by means of mechanical rollers.
  • Such prior art method required precise mechanical adjustment, produced variable results, was limited to large foil thicknesses and was insulated in a separate process thus making it extremely difficult to make and wind a coil on the fly.
  • Another alternative to obtaining relatively smooth turn edges for foil conductors was by the use of static electricity or by electrically burning the edges, which was a slow and expensive process. Again it required a separate step for insulating the conductor.
  • the present invention provides a relatively simple method for obtaining smooth and rounded turn edges. It also has the additional advantage of adding un-insulated filler foil strips to increase the conductor cross-sectional area. This is illustrated in Figs. 5 and 6. In Fig 5 it will be seen that a length of foil conductor material 30 has been bonded to a corresponding length of insulating material 32 to provide a length of flat composite foil conductor/insulation 34 that has been folded longitudinally into a substantially "U" shaped length having a central portion 36 between two leg portions 38 and 40.
  • An un-insulated filler foil conductor strip 42 is disposed centrally in the folded insulated foil conductor after which the leg portions 38 and 40 of the "U" are folded inwardly to the position substantially parallel to the horizontal central portion of the "U” to bring the free ends 38a, 40 a of the leg portions into opposing relation, as shown in Fig. 6, to provide a folded insulated foil conductor 44 having the conductor cross-sectional area increased by the cross-sectional area of the filler foil conductor 42.
  • the use of the filler strip 42 in Figs.5 and 6 not only allows the conductor cross-sectional area to be increased but it also enables the use of dissimilar conductor materials. For example, it allows one to use a copper outer wrap 30 and an aluminum strip inner filler 42.
  • the present method also has the advantage that the width of the folded insulated foil conductor may be varied without changing the width of the conductor and insulation materials. This is accomplished by during the first folding step, Fig.
  • the width of the central portion 16 of the "U” is increased and the length of the two leg portions 18 and 20 are correspondingly decreased so that when the leg portions of the "U” are folded inwardly to a position substantially parallel to the central portion of the "U” , Fig. 4, the free ends 18a, 20a of the leg portions 18 and 20 are spaced apart a distance corresponding to the increased width of the central portion 16 of the "U”.
  • This variation in the method may also be utilized in connection with the addition of the un-insulated filler foil strip 42 in Figs. 5 and 6.
  • the width of the filler strip 42 will be increased correspondingly with the increase in width of the central portion 36 of the "U".
  • the present invention provides a method for producing various insulated conductor sizes during the transformer coil winding process by simply slitting and folding standard insulating sheet materials and foil sheet conductor on the fly. By slitting on the fly any foil width can be folded into near any cross-sectional size.
  • the present invention also includes a method for varying the conductor cross-sectional area by folding the foil sheet conductor over additional filler foil strips.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Insulating Of Coils (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Insulators (AREA)
  • Manufacturing Of Electric Cables (AREA)
  • Insulated Conductors (AREA)

Claims (17)

  1. Procédé de fabrication d'un conducteur en feuille isolée pliée, comprenant les étapes suivantes :
    on met en liaison une certaine longueur d'isolant en feuille (12) avec une longueur correspondante d'un matériau conducteur en feuille (10) pour fournir une certaine longueur de conducteur / isolant en feuille composite (14),
    on plie longitudinalement la certaine longueur de conducteur / isolant en feuille composite en une longueur sensiblement en forme de U ayant une partie centrale entre deux parties en branches,
    on insère au moins une bande de conducteur en feuille de remplissage non isolée dans la longueur en forme de U avant de replier les parties en branches du "U", pour accroítre la zone de section transversale de conducteur du conducteur en feuille isolée pliée, et
    on replie les parties en branches du "U" (18, 20) vers l'intérieur jusqu'à une position sensiblement parallèle à la partie centrale du "U" pour amener les extrémités libres des parties en branches en relation d'opposition pour fournir un conducteur en feuille isolée pliée ayant deux épaisseurs de conducteur entourées d'une isolation.
  2. Procédé selon la revendication 1, dans lequel la bande de conducteur en feuille de remplissage non isolée est de largeur correspondant à la partie centrale du "U".
  3. Procédé selon l'une des revendications 1 et 2, comprenant les étapes consistant à :
    amener une certaine longueur de matériau isolant en feuille à un poste d'assemblage, et
    amener une certaine longueur de matériau conducteur en feuille au poste d'assemblage,
    et où la dite étape de liaison est effectuée au poste d'assemblage, et dans lequel les extrémités libres des parties en branches sont mises selon une relation sensiblement de butée.
  4. Procédé selon l'une des revendications 1 à 3, dans lequel la longueur première citée de matériau conducteur en feuille et la bande de conducteur en feuille de remplissage non isolée sont constituées des mêmes matériaux conducteurs.
  5. Procédé selon l'une des revendications 1 à 3, dans lequel la longueur première citée de matériau conducteur en feuille et la bande de conducteur en feuille de remplissage non isolée sont constituées de matériaux conducteurs différents.
  6. Procédé selon la revendication 5, dans lequel l'un des dits matériaux conducteurs est le cuivre et l'autre matériau conducteur est l'aluminium.
  7. Procédé selon l'une des revendications 5 et 6, dans lequel la longueur première citée de matériau conducteur en feuille est de l'aluminium et la bande de conducteur en feuille de remplissage non isolé est du cuivre.
  8. Procédé selon l'une des revendications précédentes, comprenant les étapes supplémentaires de :
    fendre un matériau conducteur en feuille en une largeur déterminée, et
    fendre un matériau isolant en feuille en une largeur correspondante.
  9. Procédé selon la revendication 8, dans lequel le matériau conducteur en feuille et le matériau isolant en feuille sont tous deux déplacés pendant les étapes de fente des matériaux.
  10. Procédé selon la revendication 9, dans lequel le matériau isolant en feuille et le matériau conducteur en feuille sont tous deux déplacés pendant les étapes de mise en liaison.
  11. Procédé selon l'une des revendications 8 à 10, dans lequel le matériau isolant en feuille et le matériau conducteur en feuille se déplacent pendant toutes les étapes du procédé de fabrication du conducteur en feuille isolée pliée.
  12. Procédé selon l'une des revendications 8 à 11, dans lequel la largeur du conducteur en feuille isolée pliée varie sans changer la largeur des matériaux conducteur et isolant, de sorte que, pendant la première étape de pliage, la largeur de la partie centrale du "U" est accrue et la longueur des deux parties en branche décroít de façon correspondante de sorte que, lorsque les parties en branche du "U" sont repliées vers l'intérieur jusqu'à une position sensiblement parallèle à la partie centrale du "U", les extrémités libres des parties en branche sont écartées d'une distance correspondant à la largeur accrue de la partie centrale du "U".
  13. Conducteur en feuille isolée pliée pour des transformateurs de distribution, comprenant une certaine longueur de matériau d'isolation en feuille (12) en liaison avec une longueur correspondante de matériau conducteur en feuille (10) pour fournir une longueur de conducteur / isolant en feuille composite plate (14), la longueur de conducteur / isolant composite (14) étant pliée longitudinalement en longueur sensiblement en forme de U ayant une partie centrale (16) entre deux parties en branches (18, 20), et les parties en branches (18, 20) du "U" étant repliées vers l'intérieur jusqu'à une position sensiblement parallèle à la partie centrale horizontale (16) du "U" pour amener les extrémités libres (18a, 20a) des parties en branches (18, 20) en relation opposée pour fournir un conducteur en feuille isolée pliée ayant deux épaisseurs de conducteur entourées par un isolant, et où le conducteur en feuille isolée pliée comprend en outre une bande de conducteur en feuille de remplissage non isolée (42) disposée de façon centrale dans le conducteur en feuille isolée pliée pour accroítre la zone de section transversale de conducteur du conducteur en feuille isolée pliée.
  14. Conducteur en feuille isolée pliée selon la revendication 13, dans lequel la longueur première citée de matériau conducteur en feuille (10) et la bande de conducteur en feuille de remplissage non isolée (42) sont constituées des mêmes matériaux conducteurs.
  15. Conducteur en feuille isolée pliée selon la revendication 13, dans lequel la longueur première citée de matériau conducteur en feuille (10) et la bande de conducteur en feuille de remplissage non isolée (42) sont constituées de matériaux conducteurs différents.
  16. Conducteur en feuille isolée pliée selon la revendication 15, dans lequel l'un des matériaux conducteurs est le cuivre et l'autre matériau conducteur est l'aluminium.
  17. Conducteur en feuille isolée plié selon l'une des revendications 15 et 16, dans lequel la longueur première citée de matériau conducteur en feuille (10) est de l'aluminium et la bande de conducteur en feuille de remplissage non isolée (42) est du cuivre.
EP99934089A 1998-07-21 1999-07-16 Conducteur feuillete isole plie et son procede de fabrication Expired - Lifetime EP1099228B1 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US09/119,791 US6080935A (en) 1998-07-21 1998-07-21 Folded insulated foil conductor and method of making same
US119791 1998-07-21
PCT/US1999/016114 WO2000005729A1 (fr) 1998-07-21 1999-07-16 Conducteur feuillete isole plie et son procede de fabrication

Publications (3)

Publication Number Publication Date
EP1099228A1 EP1099228A1 (fr) 2001-05-16
EP1099228A4 EP1099228A4 (fr) 2002-01-23
EP1099228B1 true EP1099228B1 (fr) 2005-04-20

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP99934089A Expired - Lifetime EP1099228B1 (fr) 1998-07-21 1999-07-16 Conducteur feuillete isole plie et son procede de fabrication

Country Status (8)

Country Link
US (1) US6080935A (fr)
EP (1) EP1099228B1 (fr)
JP (1) JP2002521813A (fr)
KR (1) KR100391775B1 (fr)
AT (1) ATE293833T1 (fr)
CA (1) CA2338237C (fr)
DE (1) DE69924850T2 (fr)
WO (1) WO2000005729A1 (fr)

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CA2735987A1 (fr) * 2008-09-03 2010-03-11 Usg Interiors, Inc. Module conducteur de l'electricite
MX2011002175A (es) * 2008-09-03 2011-04-07 Usg Interiors Inc Cinta electricamente conductora para paredes y techos.
MX2011002174A (es) * 2008-09-03 2011-04-07 Usg Interiors Inc Elemento electricamente conductor, sistema y metodo de fabricacion.
CN106251987B (zh) * 2011-10-31 2018-12-04 3M创新有限公司 将绝缘材料施加到电力电缆的纵向边缘的方法
DE102015212692B3 (de) * 2015-07-07 2016-11-10 Osram Gmbh Verbundbauteil und Verfahren zum Herstellen eines Verbundbauteils
JP6418095B2 (ja) * 2015-07-21 2018-11-07 株式会社オートネットワーク技術研究所 シールド導電路
JP6822252B2 (ja) * 2017-03-22 2021-01-27 三菱マテリアル株式会社 コイル及びその製造方法
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JP2021034296A (ja) * 2019-08-28 2021-03-01 株式会社デンソー 導線およびコイル部材

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Also Published As

Publication number Publication date
EP1099228A4 (fr) 2002-01-23
DE69924850T2 (de) 2006-03-02
KR100391775B1 (ko) 2003-07-16
CA2338237A1 (fr) 2000-02-03
US6080935A (en) 2000-06-27
CA2338237C (fr) 2006-10-03
ATE293833T1 (de) 2005-05-15
KR20010079553A (ko) 2001-08-22
WO2000005729A1 (fr) 2000-02-03
DE69924850D1 (de) 2005-05-25
JP2002521813A (ja) 2002-07-16
EP1099228A1 (fr) 2001-05-16

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